Ceiling grid system with interlocked joints

ABSTRACT

A sub-ceiling grid system in which the splices or joints in the main and intersecting runners are interlocked on assembly without the use of clips.

[ Oct. 30, I973 CEILING GRID SYSTEM WITH 52/669 X Drackett............................... 52/668 2,672,658 3/1954 Pedersen.... 3,031,042 4/1962 INTERLOCKED JOINTS [75] Inventor: Rolando T. Curtis, Los Angeles,

Calif; FOREIGN PATENTS OR APPLICATIONS Integrated Ceilings, Inc., Los

477,070 0/1929 Germany 287/l89.36 A

[73] Assignee:

Angeles, Calif. 3

Oct. 20, 1971 Frank L. Abbott Assistant Examiner-Carl D. Friedman Primary Examiner-- [22] Filed:

Attorney-Bernard Kriegel Appl. No.: 190,957

[52 52/668, 52/483, 287/l89. 36 A [51] Int.

T C A R T S B A 7? 5 .l nn 9 8 m J 0 %2 Ms 8 4 m4 4 l $5 7 "4 m7 "6 b6 N i m M f2 05 M .w F I. 8 5

A sub-ceiling grid system in which the splices or joints in the main and intersecting runners are interlocked on assembly without the use of clips.

3,356,402 52/664 X 2 Claims, 8 Drawing Figures Sub-ceiling structures are known wherein structural members, such as T-bars, which may be inverted so that the T-head forms a bottom flange projecting laterally from opposite sides of a vertical web, are suspended from an overhead ceiling or other structure by suitable hangers, such as wires, and comprise main runners intersected by and connected with other runners, referred to as cross runners. Most generally, such main and intersecting cross runners are arranged to form a grid system having rectangular openings defined between the runners. Lighting or other fixtures, ceiling panels or light diffusers are supported by the T-bars. In some instances, light diffusing grids or other members may be supported or hung on the vertical webs.

In any event, the grid systems provide sub-ceiling supporting means which enable ease' of access to the space above the grid system, as may'be necessary for replacing or repairing fluorescent lights and fixtures. It is customary to employ clips for interlocking the main and intersecting runners at the joints or intersections. While suchclips, for example, the clips more particularly disclosed in US. Letters Patent No. 3,185,833, have been quite satisfactory, they inherently pose problems. Since the clips occupy space, the support flange or T-head must be made correspondingly wider, with the result that the grid runners are more readily apparent. Thus, if the T-head can be reduced in its lateral width, the aesthetic quality of a finished ceiling may be enhanced.

Usually, main runners and cross runners may be of standard lengths, sometimes requiring splicing of adjacent runner ends to provide longer runners, and the use' of clips or spiral fasteners has also been necessary to retain the spliced ends interconnected with the other runner.-

When an access openingin the ceiling is necessary, having dimensions larger than theopenings defined between the main and cross runners or intersecting runners, the usual clips must be removed to allow removal of one or more cross runners or intersecting runners. Of course, the clips so removed must also be replaced later, requiring time and labor which adds to the cost of the maintenance or repair work being performed. Moreover, the initial assembly of the grid systems using clips requires additional time and labor.

The present invention provides a ceiling grid system made up of main runners and cross runners or intersecting runners which are joined or interconnected by splices without requiring clips to connect the cross runners or intersecting runners to the main runners.

Various advantages stem fromthe clipless grid system of the present invention. For example, mainand cross runner sections of standard lengths may be easily and conveniently spliced and assembled to provide a grid of various dimensions or spans. When the grid runners are of the inverted T-bar form, to enable the T-head to support light diffusers or other panels or fixtures, the T- head can be narrower laterally than is the case when clips must be employed, thereby efiecting a savings in weight and material, and also rendering the grid structure less apparent. In addition, the absence of the need for manufacturing and installing clips results in savings of time and labor for assembly or later disassembly of one or more cross or intersecting runners when access to the space between the grid and the overhead ceiling IS necessary.

In accomplishing the foregoing, the present invention contemplates the provision of main and intersecting sub-ceiling grid runners which are so constructed that joints or connections between the runners involve laterally interengageable runner end portions and cooperative portions on another intersecting runner which confine the aforementioned end portions against lateral separation. Each joint of an intersecting or cross runner is locked by verticalmovement of an intersecting runner into engagement witha main runner, whereby the intersecting runners or cross runners are easy to assemble without use of special clips or tools. Also, the runners may be verticaly removed to afford a larger access opening than the opening defined by the runners themselves.

The objectives of the invention, therefore, include the provision of sub-ceiling grid runners and a subceiling grid which are less costly to produce and assemble, which enable the construction of grids of various dimensions from standard length runners, which enhance'the aesthetic qualities of a finished ceiling, and which facilitates access to the space above the ceiling.

The invention possesses many other advantages, and has other purposes which may be made more clearly apparent from a consideration of a form in which it may be embodied. One such form is shown in the accompanying drawings forming part of the present specification. This form will now be described in detail for the purpose of illustrating the general principles of the invention, but it is to be understood that such detailed description is not to be taken in a limiting sense.

Referring to the drawings:

FIG. 1 is an isometric view of a portion of a subceiling grid made and assembled in accordance with the invention;

FIG. 2 is an exploded isometric view, showing a variety of runner end splices and cooperative locking portions of the main and intersecting runners of FIG. 1;

FIG. 3 is a fragmentary vertical section, as taken on the line 3-3 of FIG. 1;

FIG. 4 is a fragmentary vertical section, as taken on the line 44 of FIG. 3;

FIG. 5 is a fragmentary vertical'section, as taken on the line 5-5 of FIG. 1;

FIG. 6 is a fragmentary vertical section, as taken on the line 6-6 of FIG. 5;

FIG. 7 is a fragmentary exploded isometric view showing a main runner splice; and

FIG. 8 is a fragmentary exploded isometric view showing an intersecting runner splice.

As seen in the drawings, the invention is embodied in a sub-ceiling grid G, an assembled portion of which is shown in FIG. 1. The sub-ceiling grid G is composed of main runners M and intersecting runners I, joined together without the use of the usual clips, as will be later described. The illustrated grid is the typical form involving the main grids M being arranged in horizontal, parallel relation and suitably supported from above, as, for example, by hanger wires H which have their ends 10 looped through eyes 11 formed in the main runners. In this form, the intersecting orcross runners l are also arranged in parallel relation and intersect the main runners M at right angles. Thus, the grid assembly defines rectangular or square openings. It will be understood I that the main runners M and intersecting runners I may be arranged and interconnected in such other manners as to provide a variety of geometrical patterns, since the invention is concerned more particularly with the means for interconnecting and joining splicing runners at intersections without requiring clips or other fastening devices to maintain the assembled components in a rigid grid structure, bu whereby selected intersecting runners I may be easily removed from the main runners M to provide an access opening of a desired or necessary size.

A common form of runner, both main and intersecting runner, is an inverted T-bar, and thus inverted T- bars are illustrated herein. The main runners M have vertical webs 12, at the base ofwhich is the T-head flange 13 which extends laterally from opposite sides of the web 12 to provide shoulders 14. Correspondingly;

the intersecting or cross runners I have vertical webs 15 at the base of which are T-head flanges 16 which extend laterally from opposite sides of the web 15 to provide shoulders 17. The shoulders 14 and 17 on the respective runners M and I cooperate to provide a marginal shelf or ledge about the openings defined between the runners on which suitable ceiling panels, light diffusers, or the like, may rest. As will become more apparent, grid runners may be made in accordance with the invention having cross-sectional forms other than the illustrated T-form, the main point being that the runners are interconnected at joints or splices so as to be self-interlocked against inadvertent separation, and so that lengths of the runners may be assembled in a grid structure of selected dimensions.

The grid G, as shown in FIG. 1, has certain of its main runners M provided with main runner splices MS, shown in more detail in FIGS. 2, 3, 4 and 7, and has certain of its intersecting runners I provided with intersecting runner splices IS, shown in more detail in FIGS. 2, 5, 6 and 8. In each case, the main runner splices MS are locked in joined relation by cooperative portions of the intersecting runners I, and the intersecting runner splices IS are locked in joined relation by cooperative portions of the main runners M.

The typical main runner splice MS involves laterally interengageable components on adjacent ends of main runner sections. In the preferred form, these laterally interengageable components comprise a component 20 projecting from the end of one main runner section and a component 21 projecting from the adjacent end of another main runner section. The components 20 and 21 are complemental and laterally coengageable in such a manner that the runner sections are held against relative longitudinal separation. More specifically, the component 20 is shown as an L-shaped longitudinal projection which provides a surface 22 on a lug 23 projecting vertically in spaced relation to a-vertical end surface 24 and forming anotch 25. The bottom wall 26 of the component 20 is spaced above'the bottom of the runner to provide a vertical end wall 27 beneath the component 20. The other splice component 21 is also an L-shaped projection having a vertically projecting surface 28 formed on a lug 20 and opposing a vertical end surface 31 on the runner web 12 to form a notch 32 corresponding in form and dimensions with the lug 23 previously described. A longitudinally extended slot 33 extends inwardly from the end of the runner section between the lug 29 and a lower surface 34 spaced above the lower edge of the runner section and providing an end surface 35 opposing the end surface 27 of the companion runner section.

Thus, as best seen in FIGS. 2, 3 and 7, when the runner sections are moved laterally into longitudinal alignment, from the positions of FIG. 7 to the positions of FIGS. 2 and 3, the opposing surfaces 22 and 28 of the lugs 23 arid 29, respectively, prevent relative longitudinal separation of the splice or joint. When the main runner sections are thus spliced, they are positioned to beinterlocked against lateral separation by cooperative portion of an intersecting or cross runner I.

As shown, the cooperative portions of the intersecting runner I, which interlocks with the main runner splice MS, consists of longitudinally spaced surfaces 37 and 38 defining a vertical slot 39 opening upwardly from the bottom of the intersecting runner I. There is such a slot 39 in each intersecting runner I at each intersection of an intersecting runner with a main runner, and at each such intersection the main runner M has a downwardly opening notch 40. Where the intersection includes a mainrunner splce MS, the slot 40 is defined by the end surface 24 of one main runner section and the opposing end surface 41 on the projection 21 of the companion main runner section. At the main runner splices MS, lateral separation of the main runner sections is precluded upon engagement of the intersecting runner I with the companion or mating portions of the main runner sections by engagement of opposing surfaces 37 and 38, which define the notches 39, with the vertically extended laterally facing surfaces 42 and 43 of the main runner sections. The main runners M and the intersecting runners I, as shown, are inverted T-bars and the slots 39 are widened longitudinally of the intersecting runners I at the T-head 16, thereby providing, also, opposing surfaces 37a and 38a adapted to oppose the laterally facing surfaces of the T-head flanges 13, as best seen in FIG. 4, for example.

Referring to FIGS. 2, 5, 6 and 8, more particularly, it will be seen that at certain intersections, between main runners M and intersecting runners I, the intersecting runner splices IS'are generally similar to the main runner splices MS. Thus, one end of an intersecting runner has an L-shaped projection providing a vertcally projecting surface 122 formed on a lug 123 and defining with a vertical surface 124 an upwardly opening notch 125. The companion L-shaped projection 121 on the other intersecting runner section has a vertically projecting surface 128 formed on a downwardly extended lug 129 adapted to abut with the surface 122 of the lug 123 when the projections 120 and 121 are joined together, to prevent longitudinal separation of the spliced intermediate runner sections. The portion 121 has a vertical surface 131 opposing the surface 128 and forming a notch 132 opening downwardly to receive the lug 123 of the portion 120. It will also be noted that, when an intermediate runner splice IS is employed, the downwardly opening slot 39 is formed in the lug 123 for receiving the main runner web 12, or the portions 20 and 21 of a main runner splice MS, de-

' pending on whether a main runner splice MS and an intersecting runner splice IS are at a common intersection, as in the left-hand intersections in FIGS. 1 and 2.

Thus, when an intersecting runner I is joined at a splice IS and lowered vertically onto a main runner M, either at a main runner splice MS or at any other intersection, the longitudinally interlocked portions 120 and 122 will be received in an upwardly opening slot 40,

and locked against lateral separation by the opposing surfaces which define the slot 40, as, for example, the opposing surfaces 24 and 41 of a main runner splice MS. r

From the foregoing, the mode of laterally assembling the main runners M and locking the main runner splices against lateral separation by installing the intersecting runners, as well as the mode of also interlocking the intersecting runner splices together against lateral separation, is believed to be clear without need of further specific description. It is also clear that the splice construction is such that the grid G can be quickly assembled from runners of standard lengths, without need for special fasteners or clips, and that the grid is rugged, yet facilitates rapid access to the space above the grid by removal of intersecting grids, wherever necessary. in addition, when any section of a main runner is free of intersecting runners between adjacent splices, that main runner section may also be laterally removed from the grid assembly.

I claim:

1. In sub-ceiling grid apparatus: laterally spaced inverted T-bar m'ain runners; laterally 'iidinverted T-bar interconnecting runners crossing said main runners and adapted to be supported by said main runners; said T-bar runners including lower horizontal flanges; a main runner splice between adjacent end portions of aligned main runner sections; an intersecting runner splice between adjacent end portions of aligned intersecting runner sections; each main runner splice comprising a first planar L-shaped lower portion of a first main runner section having an upwardly extending first lug, a second planar L-shaped upper portion of a second adjacent main runner section having-a downwardly extending second lug interlocked with said first lug to interconnect said first and second main runner sections in alignment with each other; said second lug being spacedfrom an opposed vertical surface in said first section to providea first vertical slot extending upwardly from said first L-shaped lower portion and opening upwardly through an upper terminal surface of said main runner splice; each intersecting runner splice comprising a third planarL-shaped lower portion of a third intersecting runner section having an upwardlyextending third lug, a fourth planar L-shaped upper portion of a fourth adjacent intersecting runner section having a downwardly extending fourth lug interlocked with said third lug to interconnect said third and fourth intersecting runner sections in alignment with each other; said third L-shaped lower portion having a second vertical slot opening downwardly through a lower terminal surface of said intersecting runner splice; whereby relative vertical shifting of said main and intersecting runners toward each other places said intersecting runner splice in said first vertical slot and said main runner splice in said second vertical slot with said main runner splice straddling said third and fourth intersecting runner sections and said intersecting runner splice straddling said first and second main runner sections to retain said first and second lugs interlocked and zontal flanges of one of said runners being removed at its splice to enable such lower flanges to be disposed on opposite sides of and coplanar with the lower horizontal flanges of the other of said runners at its splice.

2. In apparatus as defined in claim 1; in which the flanges are removed from theintersecting runner to enable the intersecting runner flanges to be disposed on opposite sides of and coplanar with the lower horizontal flange of said main runner at its splice. 

1. In sub-ceiling grid apparatus: laterally spaced inverted Tbar main runners; laterally spaced inverted T-bar interconnecting runners crossing said main runners and adapted to be supported by said main runners; said T-bar runners including lower horizontal flanges; a main runner splice between adjacent end portions of aligned main runner sections; an intersecting runner splice between adjacent end portions of aligned intersecting runner sections; each main runner splice comprising a first planar Lshaped lower portion of a first main runner section having an upwardly extending first lug, a second planar L-shaped upper portion of a second adjacent main runner section having a downwardly extending second lug interlocked with said first lug to interconnect said first and second main runner sections in alignment with each other; said second lug being spaced from an opposed vertical surface in said first section to provide a first vertical slot extending upwardly from said first L-shaped lower portion and opening upwardly through an upper terminal surface of said main runner splice; each intersecting runner splice comprising a third planar L-shaped lower portion of a third intersecting runner section having an upwardly extending third lug, a fourth planar L-shaped upper portion of a fourth adjacent intersecting runner section having a downwardly extending fourth lug interlocked with said third lug to interconnect said third and fourth intersecting runner sections in alignment with each other; said third L-shaped lower portion having a second vertical slot opening downwardly through a lower terminal surface of said intersecting runner splice; whereby relative vertical shifting of said main and intersecting runners toward each other places said intersecting runner splice in said first vertical slot and said main runner splice in said second vertical slot with said main runner splice straddling said third and fourth intersecting runner sections and said intersecting runner splice straddling said first and second main runner sections to retain said first and second lugs interlocked and said third and fourth lugs interlocked; the lower horizontal flanges of one of said runners being removed at its splice to enable such lower flanges to be disposed on opposite sides of and coplanar with the lower horizontal flanges of the other of said runners at its splice.
 2. In apparatus as defined in claim 1; in which the flanges are removed from the intersecting runner to enable the intersecting runner flanges to be disposed on opposite sides of and coplanar with the lower horizontal flange of said main runner at its splice. 